Graco LRT PD44 Setup And Operation Download

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313877G

Setup - Operation

PD44

Control Box

Meter, mix and dispense system for precise two-component micro-dispensing of sealants
and adhesives. Not for use in explosive atmospheres.

See page 3 for model information, including maximum
working pressure and approvals.

Important Safety Instructions

Read all warnings and instructions in this
manual. Save these instructions.

Micrometer PD44 and LRT PD44 Control Box shown

Summary of Contents for LRT PD44

Page 1: ...spensing of sealants and adhesives Not for use in explosive atmospheres See page 3 for model information including maximum working pressure and approvals Important Safety Instructions Read all warnings and instructions in this manual Save these instructions Micrometer PD44 and LRT PD44 Control Box shown EN ...

Page 2: ... 20 Shot Size Screen Motor Driven PD44 Only 21 Level 1 Control Screen 22 Level 2 Control Screen 23 Purge Timer Screen 25 Status Screen 28 Motor Status Screen Motor Driven PD44 only 30 Motor Error Codes Screen Motor Driven PD44 Only 32 Supervisor Screen LRT PD44 Only 33 Supervisor Screen Motor Driven PD44 Only 34 Supervisor Help Screen Motor Driven PD44 Only 35 Calibration Screen LRT PD44 Only 36 P...

Page 3: ...s Steel Pumps 308167 Low Volume Air Regulators 308168 High Volume Air Regulators 308169 Air Filters Lubricators and Kits 309306 Air Operated Husky Diaphragm Pumps 312376 Stainless Steel Agitator Kit 313526 Check Mate Pump Packages 406088 Check Mate Ram Packages PD44 Control Box Model Max Air Working Pressure psi MPa bar Voltage Linear Resistive Transducer LRT 100 0 7 7 120 240V 50 60Hz Micrometer ...

Page 4: ...s equipment includes but is not limited to Protective eyewear Clothing and respirator as recommended by the fluid and solvent manufacturer Gloves Hearing protection FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lig...

Page 5: ...r under pressure Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from t...

Page 6: ... 1 3 4 2 EXT LOAD DISP RET 106 VALVE 108 107 SPOOL 105 CYLINDER AIR D Key A Emergency Stop B Control Power Switch C Touch Panel D Alarm Speaker E Power Input F Start Options Connection G Custom I O H A Tank Level Controls Connection J B Tank Level Controls Connection K Main Air Inlet L Dispense Valve I O Connection M Spool Valve Load Connection N Spool Valve Dispense Connection P Air Cylinder Exte...

Page 7: ... WITH VOLTAGE SWITCH SETTING VALVE I O MOTOR 3 2 4 1 AUDIO ALARM START OPTIONS Key A Emergency Stop B Control Power Switch C Touch Panel D Alarm Speaker E Power Input F Start Options Connection H A Tank Level Controls Connection J B Tank Level Controls Connection L Dispense Valve I O Connection U Motor Connection B A C D H J E F L U ...

Page 8: ...Component Identification 8 313877G PD44 Dispense Valve See PD44 Operation manual 313876 for detailed dis pense valve component identification and instructions FIG 3 PD44 Micrometer Dispense Valve ...

Page 9: ... properly installed and grounded in accordance with all local codes and ordinances Hard wired units the grounding wire must be used All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations Air and fluid hoses use only electrically conductive hoses Fluid supply container follow local code Solvent pails used when flushing follow local code Use onl...

Page 10: ...Retract Yellow Dispense Green Reload 7 2 5 3 4 6 1 7 2 5 3 4 6 1 7 2 5 3 4 6 1 1 2 5 6 3 7 12 9 13 10 14 11 8 4 SIGNAL CONNECTION PG 3 A TANK LEVEL CONTROLS PG 4 B TANK LEVEL CONTROLS PG 2 CUSTOMER I O 100V TO 250V AC PG 8 START MACHINE I O PG 1 1 3 4 2 EXT LOAD DISP RET 106 VALVE 108 107 SPOOL 105 CYLINDER AIR 7 2 5 3 4 6 1 7 2 5 3 4 6 1 7 2 5 3 4 6 1 1 2 5 6 3 7 12 9 13 10 14 11 8 4 SIGNAL CONNE...

Page 11: ...djust customer supplied air pressure regulator to 80 psi 0 6 MPa 6 bar 3 Perform Setup procedure for dispense valve and feed system components See Related Manuals on page 3 NOTICE Feed system and main logic control system must use separate air supplies VERIFY INCOMING VOLTAGE BEFORE CONNECTING POWER WITH VOLTAGE SWITCH SETTING VALVE I O MOTOR 3 2 4 1 AUDIO ALARM START OPTIONS ...

Page 12: ...hot selection resets to 0 The operator must then select a shot NOTE On Micrometer PD44s skip steps 4 7 4 Navigate to the Shot Size screen 5 Select a shot number 6 Navigate to the Pump Mode screen NOTE Upon power up Error Code 130 Position Mod ule is not Enabled will be shown Press the Retract Home button to allow the dispense valve metering rod connecting block to move to the reload position 7 Pre...

Page 13: ...vigate to the Posidot Control screen On Motor Driven PD44s navigate to the Metering Valve Control screen 2 Under Posidot Mode press the Retract button 3 Press the Continuous button 4 On Micrometer and LRT PD44s press and release the start device Under Posidot Mode press the Retract button to stop dispensing and retract the metering rods On Motor Driven PD44s press and hold the start device to disp...

Page 14: ...agrams Micrometer PD44 LRT PD44 FIG 4 Main Screen Posidot Control Level 1 Control Level 2 Control Purge Timer Status FIG 5 Main Screen Posidot Control Shot Size Flow Rate Level 1 Control Level 2 Control Purge Timer Status Supervisor Calibration Calibration Help ...

Page 15: ...peration 313877G 15 Motor Driven PD44 FIG 6 Main Screen Metering Valve Control Shot Size Flow Rate Level 1 Control Level 2 Control Purge Timer Status Supervisor Supervisor Help Motor Status Motor Error Codes ...

Page 16: ...r Driven PD44 only The password button enables the user to changes values in certain screens To access the password press the Password Access button shown as 0000 When the keyboard appears enter password 5810 then press the Enter key Error Code Motor Driven PD44 only NOTE The Error Code button is shown on every screen on the Motor Driven PD44 On all screens that it is shown the Error Code button r...

Page 17: ...e selected when the pump is idle for a long period of time Shot Mode The machine fully cycles the number of times displayed in the Cycle Counter field when the start device is pressed and released The machine cycles continuously when the start device is pressed and held Continuous Mode The machine continually cycles the pumps when the START DEVICE is pressed Purge Timer On Off See Purge Timer scre...

Page 18: ...ston page 13 Retract Mode The air cylinder and pumps immediately retract and remain in the retracted position This is used for mainte nance purposes only Extend Mode The air cylinder and pumps immediately extend and remain in the extended position This position must be selected when the pump is idle for a long period of time Shot Mode The machine cycles the number of times displayed in the Cycle C...

Page 19: ...optional dispense valve OPEN In this mode the dispense valve is held in the open position allowing material to pass through AUTO In this mode the dispsense valve opens automatically whenever the pump is cycled CLOSE In this mode the dispense valve is held closed ...

Page 20: ...The new shot size percentage appears in the Shot Size field Select Shot Size button The Select Shot Size button allows the operator to choose one of the ten preset shot sizes seen in the Shot Size 1 10 section Number of Strokes This displays the number of strokes needed to perform the selected shot If the Shot Size selected is 150 then Number of Strokes displays a 2 because the machine performs tw...

Page 21: ... in percent of stroke For example if the purge shot size is set at 340 Amount Per Stroke displays 85 00 and Number of Strokes During Purge displays a 4 Shot Size percent Flow Rate mm sec These are the 7 preset Shot Size percent and Flow Rate mm sec values Shot size is in percent of stroke The preset values can be selected using Select Shot Size Flow Rate Combination To edit the preset Shot Size or...

Page 22: ...noperable if the high level automatic tank refill ing feature was not purchased with this machine Stop Fill button This button stops the automatic tank refilling process for both the A and B component material tanks Micrometer PD44 and LRT PD44 Level 2 Control screen shown Message Description Material High The tank level is at or above the high level sen sor Material Low The tank level is below th...

Page 23: ...ensor the machine shuts down To recover refill the component tank with mate rial to above the low level sensor When 0 is displayed the low level shutdown feature is disabled Alarm Engage button When this button displays 1 and the material level of either the A component tank or the B component tank goes below the low level sensor the audible alarm is activated Auto Fill Engage button When this but...

Page 24: ...is counts up to the preset time Fill Timer NOTE If the automatic refilling option has not been pur chased the Fill Timer function is disabled This changes the delay before the Fill Timer Fault mes sage is displayed to the corresponding A Tank Status or B Tank Status field in the Level 1 Control screen If the material level reaches the tank high level sensor before the preset fill time elapses the ...

Page 25: ...form the follow ing steps 1 Select the Cycle Counter button A numeric keypad appears 2 Enter in the desired number of counts for the Cycle Counter 3 Press the Enter button The current number of cycles appears in the Cycle Counter field Purge Timer On Off The Purge Timer On Off switch is used to enable dis able the Purge Timer OFF The Purge Timer is disabled ON The Purge Timer is enabled The machin...

Page 26: ...3cc shot size 10cc gel time 10 minutes use the following equation Dwell Alarm Timer This changes the duration that the audible alarm is active prior to the purge shot being initiated To change the Dwell Timer perform the following steps 1 Select the Dwell Timer button A numeric keypad appears 2 Enter the desired Dwell Timer time in seconds Use the button to enter tenths of seconds 3 Press the butt...

Page 27: ...Amount Per Stroke LRT and Motor Driven PD44 only This displays the percent of the stroke used during a shot For example if the shot size is set at 150 Number of Strokes During Purge displays 2 and Amount Per Stroke displays 75 ...

Page 28: ...Cycle Totalizer This counter increments each time the machine cycles Number of Strokes Motor Driven PD44 Only not shown This displays the number of strokes needed to perform the currently selected shot size If the selected shot size is 150 Number of Strokes displays a 2 Amount per Stroke in Motor Driven PD44 Only not shown This displays the amount of stroke used to perform the currently selected s...

Page 29: ...is displays the status of the reload spool proximity switch If this displays a 1 the switch is activated and if this displays a 0 the switch is deactivated See Com ponent Identification section in dispense valve manual See Related Manuals on page 3 PX OSV Dispense This displays the status of the dispense spool proximity switch If this displays a 1 the switch is activated If this displays a 0 the s...

Page 30: ...sition Home Switch Home Limit Switch This displays 1 when the metering valve rod home switch is activated Upper Switch Upper Over Limit Switch Extend This displays 1 when the metering valve rod upper over travel limit switch is activated The dispense valve is in the most retracted position Lower Switch Lower Over Limit Switch Retract This displays 1 when the metering valve rod lower over travel li...

Page 31: ... in the shot mode program This is used for troubleshooting Reload Mode Step This gives the current step in the reload mode program This is used for troubleshooting Oper Mode Step This gives the current step in the operator mode pro gram This is used for troubleshooting ...

Page 32: ...HMI Operation 32 313877G Motor Error Codes Screen Motor Driven PD44 Only These screens give descriptions of the motor error codes ...

Page 33: ...ress the Enter button 4 Press the Pump Reload Position button 5 Enter the desired reload position 6 Press the Enter button 7 Press the Enter Data button Shot Size Offset Button The Shot Size Offset button sets the transducer point where the metering rods will retract The factory setting is 1 To change the Shot Size Offset setting perform the fol lowing steps 1 Press Enter Password button 2 Enter p...

Page 34: ...end of the stroke This feature is only available when in Operator Control mode For example if the selected shot size is 30 of the metering rods stroke three shots will be taken 90 of the stroke then the metering rods will retract The rods retract after three shots because it cannot do another shot without going over 100 stroke If the selected shot size is greater than 50 of the metering rods strok...

Page 35: ...13877G 35 Supervisor Help Screen Motor Driven PD44 Only This screen describes the various reload and shot options in the Supervisor screen To get to the Setup Help screen press the Help button on the Supervisor screen ...

Page 36: ... Done button This button exits Calibration mode Transducer Position This shows the transducer position in transducer units Transducer Position in This shows the transducer position in percent of stroke To calibrate the pumps perform the following steps 1 From the Calibration screen select Calibration Mode 2 Press the Extend Pumps button Pumps extend 3 Press the Teach button 4 Press the Retract Pum...

Page 37: ...HMI Operation 313877G 37 Calibration Screen Help This screen describes the calibration procedure ...

Page 38: ...e See Related Manuals on page 3 Shutdown 1 On Micrometer and LRT PD44s go to the Posidot Control screen On Motor Driven PD44s go to the Metering Valve Control screen 2 Press the Retract button 3 Press the Extend button 4 Press the Emergency Stop button Ensure every thing is off 5 Twist Emergency Stop to reset 6 Perform Pressure Relief Procedure 7 Perform feed system shutdown procedure See Related ...

Page 39: ... the Shot Size and Flow Rate Combination seen on the Shot Sizes screen See the machine logic drawings for more information Customer Signal Done Output This output activates for 2 seconds after the dispense cycle is complete Customer Signal Dis pense Ready Output This output is active when the machine is in the Shot Mode and the dispense valve is retracted and loaded with material This output deact...

Page 40: ...en Dispense valve not discharging nor mal or full volume Low material level in reservoirs Fill material reservoirs and prime the machine Air in material tanks Fill reservoirs and prime machine Material leaks past spool valves Spool valve worn or damaged Replace the spool valve and sleeve Improper material mixing Mixer not clean or free Remove and replace the mixer Material leaks around mixer while...

Page 41: ...Schematics 313877G 41 Schematics Micrometer ...

Page 42: ...Schematics 42 313877G Linear Resistive Transducer LRT ...

Page 43: ...AND 2 ON PANEL SIDE OF CONNECTOR 4 JUMPER PINS 8 AND 9 ON PANEL SIDE OF CONNECTOR 5 CABLE FROM PANEL TO PG 5 TO BE 10 FEET 6 STRIP MOTOR CABLE TO SHIELD AND CLAMP TO BACK PANEL AS SHOWN FIL 1 ZP LMT 3M 6 19 6 RPS 2M 17 6 16 1M EM 253 POSITION MODULE STP 15 6 54 LINE 55 L LOAD N 52 DRIVE I O B B A A GND GND 52 55 GND CN 4 N L1 MOTOR DRIVE PARKER E AC DRIVE 1 5 PG 5 9 8 7 6 2 4 3 1 M1 1L1 1L2 12 6 8...

Page 44: ...1 PIN HTR 1 SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE 10 14 12 13 11 9 7 8 5 6 4 NUMBER 2 3 1 PIN PIN USAGE HTR 1 SPARE SPARE SPARE SPARE SPARE SPARE SPARE 81 1060 7 25 81 1061 7 25 81 1060 7H 25 81 1061 7H 25 7 NUMBER PIN USAGE 4 5 6 2 3 PIN 1 FL 1 NOTE FILTER SUPPLIED BY CUSTOMER PD 1093 1053 1093 NOTE FILTER SUPPLIED BY CUSTOMER FL 1 ENCLOSURE GROUND ST...

Page 45: ...1 PIN HTR 1 SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE 10 14 12 13 11 9 7 8 5 6 4 NUMBER 2 3 1 PIN PIN USAGE HTR 1 SPARE SPARE SPARE SPARE SPARE SPARE SPARE 81 1060 7 25 81 1061 7 25 81 1060 7H 25 81 1061 7H 25 7 NUMBER PIN USAGE 4 5 6 2 3 PIN 1 FL 1 NOTE FILTER SUPPLIED BY CUSTOMER PD 1093 1053 1093 NOTE FILTER SUPPLIED BY CUSTOMER FL 1 ENCLOSURE GROUND ST...

Page 46: ...Schematics 46 313877G ...

Page 47: ...x 20 mm 2A time delay Graco part 81 1053 2 11 Qty 1 Motor Driven PD44 Control Box 5 x 20 mm 10A fast type F 250 VAC Graco part V 21610P Qty 2 Maximum Amperage Micrometer and LRT PD44 Control Box 2 amps Motor Driven PD44 Control Box 10 amps Dimensions H x L x W Micrometer and LRT PD44 Control Box 13 in x 12 in x 15 in 330 mm x 305 mm x 381 mm Motor Driven PD44 Control Box 20 in x 8 in x 20 in 508 m...

Page 48: ...anship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as se...

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